Certain esters of carboxy acids with oxyalkylated phenol-aldehyde resins



being of the formula I Patented Jan. 8, 1952 FFlCE QCERTAIN' limes. F CARBOXY ACIDS WITH OXYALKYLATED PHENOL-ALDE- HYDE REsINS, f J

a Melvin De" Groota: St. Louis, and Bernhard o Keiser, Webster Groves, Mo., assignors to Petrolite Corporation, Ltd, Wilmington, Del., a corporation of Delaware N 0 Drawing;

The present invention is concerned withcertain new chemical products, compounds or, composi+ tions, having useful applications in variousarts. This invention is a continuation inepartg of our co.-.pending application, Serial ,No., "726,213,- filed February, 3, 1947 and now abandoned. It in cludes methods or procedures for manufacturing said new products, compounds, or compositions, as wellas the products, compounds, or-compositions themselves. 7 r s Said new compositions are mixed esters'in which the acyl radicals include an acyl radical of a detergent-forming monocarboxy acid havingat least 8 and not over ,32 carbon atoms, in conjunction with the acyl radical of an alpha halogen monocarboxy acid having not 'overfi carbon atoms, and in which the alcoholicradical is that of certain hydrophile polyhydric syhthe'tief'p'roducts; said hydrophile synthetic products being oxyalkylation products of (A) an alpha-beta alkylene oxide having not more than 4 carbon atoms and selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide and methylglycide, and (B) an oxyalkylation-susceptible, fusible, organic solvent-soluble, water-insoluble phenol-aldehyde resin; said resin being derived-byreaction between a difunctiona'l 'monohydric phenol and an aldehyde-having'not over 8 carbon atoms and reactive toward said phenol; said resin being formed ingthesubstantial absence of .trifunctional phenols; said phenol in which R is a hydrocarbon radical having at least land not more than 12 carbon atoms and substituted in the 2,4,6 position; said oxyalkylated resin being. characterized by the introduction into the resin molecule of a plurality of di- 1: Although the herein described products have a "number of industrial. applications,- they are of particular value for resolving petroleum emul- Application December 10,1948, Serial No. 54,457

2 V sions of the water-in-oil type that are commonly referred to as. cut oil, roily oil, emulsified oil, etc., and whichcomprise finedroplets of na tu'rally-occurring waters or brines dispersed in a more or less permanent state throughout theoil which constitutes the continuous phase of the emulsion. .This specific application is described and claimed in our co-pending application, Serial No. 64,456, filed December 10, 1948, now abandoned. See also our co-pending application, Serial No. 64,469, filed December 10, 1948. V v The new products are useful as wetting, de-

tergent and levelling agents in the laundry, textile and dyeing industries; as wetting agents and detergents in the acid washing of building stone and brick; as wetting agents and spreaders in the application of asphalt in road building and the i like; as a flotation reagent in the flotation separation of various aqueous suspensions containing negatively charged particlessuch as sewage, coal washing waste water, and various trade wastes and th'e like; as germicides, insecticides, emuls ifying agents, as for example, for cosmetics, spray oils, 'water repellent textile finishes; as lubricants,etc. W

For'lpurpose of convenience what is said hereinafter will be divided into three parts. Part 1 will be concerned with the production of the resin from a difunctional phenol and an aldehyde; Part2 will be concerned'with the oxyalkylation of the resin so as toconvert it into a hydrophile hydroxylated derivative; and Part 3 will be concerned with the conversion of the immediately aforementioned derivative into a totalor partial esterrby reaction with an acid, an ester, or other functional derivative, so as to obtain a compound of the kind previously specified and subsequently described in detail. V

PART 1 As to the preparationof thephenol-aldehyde resins reference is made to our co-pending applications, Serial Nos; 8,730 and 8,731, both filed February 16, 1948 both of which are now aban- 'doned.. In such co-pending applications we described a fusible, organic solvent-soluble, water- 'insoluble resin polymer of the formula 3 In such idealized representation 11." is a numeral varying from 1 to 13 or even more, provided that the resin is fusible and organic solvent-soluble. R is a hydrocarbon radical having at least 4 and not over.,8 carbon atoms. In the instant application R may have as many as 12 carbon atoms, as

in the case of a resin obtained from a dodecyl- In the instant invention it may be first v phenol;

' densation reaction and, in fact, may operate by suitable to describe the alkylene oxidesemployed as reactants, then the aldehydes, and finally the phenols, for the reason that the latter require a more elaborate description- The alkylene oxides which :may be used are.

the alpha-beta oxides having not more than 4 carbon atoms, to wit, the alpha-beta ethylene initial combination with the aldehydic reactant. The compound: .hexamethylenetetramine illustrates such a combination. In light of these various'reactions it becomes diflicult to present any 1formula .:which:wo.uld depict the structure of the "various resins' prior to oxyalkylation. More will oxide, alpha-beta propylene: oxide, alpha-beta I butylene oxide, glycide, and methylglycide.

Any aldehyde capable of forming a methylol or I a substituted methylol group and having not more than 8 carbon atoms is satisfactory, so long-as it does not possess. some other functional group or structure which will conflict with the resinification reaction or with. the subsequent oxyalkylation of the resin, but the useof formal?- dehyde, in its cheapest formof an aqueous solution, for the production of the resins is particularly advantageous. Solid polymers of formaldehyde are more expensive and higher aldehydes are both less reactive; and are more'expensive. Furthermore, the higher aldehydes may undergo other reactions which are not desirable, thus introducing difficulties into the resinification step. Thus acetaldehyde, forexample, may undergo an aldol condensation, and-it and most of the higher aldehydes enter into self-resinification :when treated with strong acids or alkalies. On'the other hand, higher aldehydes frequently beneficially affect the solubility and fusibility of a resin. This is illustrated, for example by the different characteristics'of the resin prepared from para-tertiary amylphenol and formaldehyde on. one hand, and a comparable product prepared from the same phenolic reactant and heptaldehyde on the other hand." Theformer,

as shown in certain subsequent examples; is a hard, brittle, solid, whereas the latter 'is's'oftand tacky, and obviously easier to handle inithe subsequent oxyalkylation procedure.

Cyclic aldehydes may be employed, particularly benzaldehyde. The employment'of'furfu'ral requires careful control "for the reason that in addition to its aldehydic function, furfural can form condensations by virtue of its unsaturated structure. The productionof resinsfrom furfur'a-l for use in preparing products from the present process is most conveniently conducted with weak alkaline catalystsa'nd often; with alkali metal carbonates. Useful aldehydes, inaddition to formaldehyde, are acetaldehyde, propionic aldehyde, butyraldehyde, 2'-ethylhexanal, ethylbutyraldehyde, heptaldehyde, and benzaldehyde, furfural and glyoxal. It would appear that the use of glyoxal should be avoided .due to the. fact that it is tetrafunctional. However, our experience has been that, in resin manufacture and particularly as describedherein,xapparently only one of the aldehydic. functions enters into the resinification reaction. The .inability of the other aldehydic function to enter into the reaction is presumably due to steric hindrance. Needless to say, one can usea mixture of two or more aldehydes although usually thishas no advantage.

Resins of the kind which are used as intermediates in this invention are obtained with the be said'subse'quently as to the difference between theuse of an alkaline catalyst and an acid cat- :alyst; evenin the use of an alkaline catalyst there is considerable evidence to indicate that the products are not identical where different basic-materials are employed. The basic materials employed include not only those previously enumerated but also the hydroxides. of the alkali -m'etals, hydroxides of. the alkaline earth metals, salts of strong bases and weakacids such as=sodium acetate, etc.

Suitable 1 phenolic reactants include: the following: Para-tertiarybutylphenol;' para-secondary butylphenol; para tertiary amylphenol'; para secondary-amylphenol'; .para-tertiary-hex+ ylphenol; para-isooc'tylphenol'; ortho -phenylphenol; para-phenylphenol; orth'o benzylphenol; para-benzylphen'ol; and p'ara-cyclohexylphenol, and the corresponding ortho-para substituted metacresols and 3,5-xylenols. similarlyjone may use para-"or ortho-nonylphenol oramixture, para-' or 'decylphenol or amixture, menthylphen01, or paraor ortho-dodecylphenol.-

The phenols herein, contemplated for reaction may be indicated: by the following formula:

with' the provision as to 3-or-3,5' methyl substitution. This is conventional nomenclature, numboring" the various positions in the usual clockwise manner, beginning with the hydroxyl. posi 'tion as one:

The manufacture of. thermoplastic-:phenolealdehyde' resins, particularly from formaldehyde and'a difunctionalpheno1.-i.-e., a phenolin which product. in some cases fail to produce sufiiciently hydroone of the three reactive positions (2,4,6) has been substituted by a hydrocarbon group, andparticularly by one having at least 4 carbon atoms and not more than 12 carbon atoms, is well known. As has been previously pointed out, there is no objection to a methyl radical provided it is present in the 3 or 5 position.

These resins, used as intermediates to produce the products of the present invention are described. in detail in our Patent 2,499,370, granted March 7, 1950 and specific examples of suitable resins are those of Examples 1a through 103a of that patent, and reference is made thereto for a description of these intermediate resins and for examples thereof.

PART 2 p Having obtained a suitable resin of the kind described, such resin is subjected to treatment with a low molal reactive alpha-beta olefin oxide so as to render the product distinctly hydrophile in nature as indicated by the fact that it becomes self-emulsifiable or miscible or soluble in Water, or self-dispersible, or has emulsifying properties.

.The olefin oxides employed are characterized by the fact that they contain not over 4 carbon atoms and are selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide, and methylglycide. Glycide may be, of course, considered as a hydroxy propylene oxide and methyl glycide as a hydroxy butylene oxide.

In any event, however, all such reactants contain the reactive ethylene oxide ring and may be best considered as derivatives of or substituted ethylene oxides. The solubilizing effect of the oxide is directly proportional to the percen- .tage of oxygen present, or specifically, to the oxygen-carbon ratio.

In ethylene oxide, the oxygen-carbon ratio is 1:2. In glycide, it is 2:3; and in methyl glycide, 1:2. In such compounds, the ratio is very favorable to the production of hydrophile or surfaceactive properties. However, the ratio, in propylable in conjunction with the three more favorable alkylene oxides in all cases. For instance, after one or several propylene oxide or butylene oxide molecules have been attached to the resin molecule, oxyalkylation may be satisfactorily continued using the more favorable members of the class, to produce the desired hydrophile Used alone, these two reagents may phile derivatives because of their relatively low oxygen-carbon ratios.

Thus, ethylene oxide is much more effective .than propylene oxide, and propylene oxide is more effective than butylene oxide. Hydroxy propylene oxide (glycide) is more effective than propylene oxide. Similarly, hydroxy. butylene oxide (methyl glycide) is more effective than butylene oxide. Since ethylene oxide isthe cheapest alkylene oxide available and is reactive,

its use is definitely advantageous, and especially in light of its high'oxygen content. Propylene oxide is less reactive than"ethyleneoxidaand butylene oxide is definitely less reactive than propylene o'xide.l On the other hand, glycide may reactwith almost explosive violence and must behandled with extreme care.

The oxyalkylation of. resins of the kind from which the initial reactants used in the practice of. the present invention are. prepared is advantageously catalyzed bythe presence of an alkali. Useful alkaline catalysts include soaps, sodium acetate, sodium hydroxide, sodium methylate, caustic potash, etc. .The amount of a1- kaline catalyst usually is between 0.2% to 2%. The temperature employed may vary from room temperature to as high as 200-C., Thereaction may be conducted with .or without pressure, i. e., from zero pressure to approximately 200 oreven 300 pounds gauge pressure ,(pounds per square inch). In a general way, the method employed is substantially the same procedure as used for oxyalkylation of other organic materials having reactive phenolic groups.

It may be necessary to allow for the acidity of a resin in determining the amount of alkaline catalyst to be added in oxyalkylation. For instance, if a nonvolatile strong acid such as sulfuric acid is used to catalyze the resinification reaction, presumably after being converted into a sulfonic acid, it may be necessary and is usually advantageous to add an amount of alkali equal stoichiometrically to such acidity, and include added alkali over and above this amount as the alkaline catalyst.

It is advantageous to conduct the oxyethylation in presence of an inert solvent such as xylene, cymene, decalin, ethylene glycol diethylether, diethyleneglycol diethylether, or the like, although with many resins, the oxyalkylation proceeds satisfactorily without a solvent. Since xylene is cheap and may be permitted to be present in the final product used as a demulsifier, it is our preference to use xylene. This is particularly true in the manufacture of products from low-stage resins, i. e., of 3 and up to and including 7 units per molecule."

If a xylene solution is used in an autoclave as hereinafter indicated, the pressure readings of course represent total pressure, that is, the combined pressure due to xylene and also due to ethylene oxide or whatever other oxyalkylating agent is used. Under such circumstances it may be necessary at times to use substantial pressures to obtain effective results, for instance, pressures up to 300 pounds along with correspondingly high temperatures, if required.

However, even in the instance of high-melting resins, a solvent such asxylene can be eliminated in either one oftwo ways: After the introduction of approximately 2 or 3 111015 of ethylene oxide, for example, per phenolic nucleus, there is a definite drop in the hardness and melting point of the resin. At this stage, if xylene or a similar solvent has been added, it can be eliminated by distillation (vacuum distillation if desired) and the subsequent intermediate, being comparatively soft and solvent-free, can be reacted further in the usual manner with ethylene oxide or' some other suitable reactant.

Another procedure is to continue the reaction to completion with such solvent present and then eliminate the solvent by distillation in the customary manner.

Another suitable procedure is to use propylene oxide or butyleneoxide as a solvent-as well as a reactant in the-earlier stages along with ethylene ego-anew Ffixidf for instance; by diss'olving'the powdered resin. in propylene oxide even though oxyalkylation is taking placezto-a greater orlesseridegree. Afterfa solution" has been obtainedwhich repre'sents the original resin dissolved. in:. propylene oxide; or butyleneoxide, or. a'mixture'which includes the oxyalkylated product, ethylene ox- -ide.is' addedto'. react with the liquid .mass until -hydrophile...properties. are obtained; 1 Since ethylene oxide. ismore reactive than propylene ox- .ide. oitbutylen'eoxide, the finalpro'duct may containisomeunreacted propylene oxideor butylene oxide which can'be elimihatedby volatilization or "distillation. .in any "suitable manner. 7

' Attentionis' directed to the fact that the resins herein describedmust be fusible or soluble in an organic-solvent. Fusible resins-invariably are soluble in one ormoreorganic solvents such as those mentioned elsewhere herein.- It is to be emphasized, however, thatthe organic solvent employed to indicate or assure that the resin meets this requirement need not-be the one used in oxyalkylation. susceptible to oxyalkylation are included inthis Indeed, solvents which a are group of I organic solvents-.- Examplesof such solventsare alcohols and" alcohol-others. How'- 'ever, Where-a resin is soluble in an organiesolvent, there-are usually available other organic inafter is concerned' with" ability to' vary the hydrophile properties of the hydroxylated intermediate reactants from minimum hydrophile properties to maximum hydrophileproperties. Such properties in turn,- of course, are effected subsequently bytheacid employed for esterifica- *tion and 'the'quantitative nature of the esterification itself, i. e., whetherit is total or partial. 'It

maybe well, however, to point out what has been i said elsewhere. in regardlto the hydroxylated intermediate reactants. See, for example, our co-pending applications, -Serial Nos 8,730 and 8,731, both filed February 16,1948, and Serial No. 42,133, filed August 2, 1948, and Serial. No. 42,134, filed August 2, .1948, all fourof which are now abandoned.v The reason. is that the esterification, depending on the acid selected, may vary the hydrophile-hydrophobe balance in one direction or .the other, and also invariably causes the development of some property. which makes it inherently difierent from the two. reactants from which the derivative ester is obtained.

Referring. to the hydrophile hydroxylated intermediates, even more remarkable and. equally diflicult to explain, .are the versatility and the utility of thesecompcunds considered as chemical reactants as one goes from minimum hydrophile property to ultimate maximum hydrophile property. For instance, minimum hydrophile property may be described roughly as the point vvhere'twov ethyleneoxy radicals or moderately in excess thereof are introducedper phenolic hydroxyl. Such'minirnum hydrophile property or subsurface-activity or minimum surface-activity'mea ns thatithe product'shows at least emulsifyingpropertiesor self-dispersion in cold or even in warm:.distilled water (15 to 40- C.) inconcentrations.of-;0t5=.%1to 5.0%. Thesematerials are 'gene'rallyirmore 'soluble: in cold. water than warm water, and may even be very insoluble in boiling: waterzf Moderately high temperatures aid in reducing :the viscosity-of the solute under examination; Sometimes if one continues 1 to shaker at xhot' solution, even though cloudy or containing insoluble phase, one finds that solutionitakesu place :to, give a homogeneous phase; as the": mixture cools. Such self-dispersion tests are conducted in the absence of an insoluble solvent.

When the hydrophile hydrophobe balance is above the indicated minimum (2 moles of ethylene oxide per phenolic nucleus or theequivalent) but-insufiicient to. give a sol as. described immediately preceding, then, and in that event hydrophile properties'are indicated by the fact that one canproduce an emulsion by having present 10% to 50%-of. an inert. solvent such as xylene. All that oneneedlto do is to have a xylene solution within the range of 50 to parts by weight .ofoxyalkylated derivatives and 50 to 10' parts by I Weight of xylene andmix such solution with one,

two or three times its volume of distilled water andfshake vigorously so. as to obtain an'emul'sion whichmay be of the oil-in-water type or the water-in-oiltype (usuallytheformer) but, in any "event; is due to the hydrophile hydrophobe balance of the oxyalkylated derivative. We prefer simplyto' use the xylene. diluted derivatives, which are described elsewhere, for this test rather than evaporate the" solvent and employ any more. elaborate tests, if the solubility is not sufficient topermit the" simple sol test in water previously noted.

Iftheproduct is not readilywater' soluble it maybe dissolved'in ethyl or 'methyl alcohol,

' ethylene glycol diethylether; or diethylene glycol diethyl' ether; with a' little acetone added if required; making a rather concentrated solution, "for instance40%- to; 50%,- and then adding enough of the concentrated alcoholic or equivalent solution to give" the previously suggested 0.5%" to' 5.0% strength solution. If the product is-sel'f-'dispersing (i.'-e., if the oxyalkylated product is-aliq'ui'd or a liquid-solution self-emulsifiable), such' sol or dispersionis referred to as at least semi-stable" in thesense that sols, emulsions-,-- or dispersions prepared are relatively stable, -if they remain at least forsome period-of time, for instance 30 minutes to 1 two hours, before showing any marked separation. Such tests ar ewconducted at room temperature (22 0.).

Needless to.say; a test canbemade in presence of an insoluble sol-vent suchv as 5% to 15% of "xylene, as'noted in: previous examples. If such mixture, i."e., containing awater-insoluble solvent, is at least semi stable, obviously the sol- Surphile' hydrophobe-balance can also be-determined by'th e use of conventional measurementsherein- ,when in the higher oxyalkylated stage, and to J form an emulsion in the lower andintermediate stages of oxyalkylation.

' Allowancemust be madefor the presence of a solvent in the final product in relation to the hydrophile properties of the final product. The principle involved in the manufacture of the herein contemplated compounds for use as polyhydric reactants, is based on the conversion of a hydrophobe or non-hydrophile compound .or mixture of compounds into products which are distinctly hydrophile, at least to the extent that they have emulsifying properies or are selfemulsifying; that is, when shaken with water they produce stable or semi-stable suspensions, or, in the presence of a water-insoluble solvent, such as xylene, an emulsion. In demulsification, it is sometimes preferable to use a product having markedly enhanced hydrophile properties over and above the initial stage of self-emulsifiability, although we have found that with products of the type used herein, most efficacious results are obtained with products which do not have hydrophile properties beyond the stage of self-dispersibility.

More highly oxyalkylated resins give colloida solutions or sols which show typical properties comparable to ordinary surface-active agents. Such conventional surface-activity may be measured by determining the surface tension and the interfacial tension against paraflin oil or the like. .At the initial and lower stages of oxyalkylation, surface-activity is not suitably determined in this same manner but onemay employ an emulsification test. Emulsions comeinto existence as a rule through the presence of .a surface-active emulsifying agent. Some surfaceactive emulsifying agents such as mahogany soap may produce a water-in-oil emulsion or an oil-in-water emulsion depending upon theratio of the two phases, degree of agitation, concentration of emulsifying agent, etc.

The same is true in regard to the'oxyalkylated resins herein specified, particularly in the lower stage .of oxyalkylation, the so-called .sub-sur-. face-active stage. The ,surfaceeactiveproperties arev readily demonstrated by producing a xylene-water emulsion. A suitable procedure is as follows: The oxyalkylated resin is dissolved in an equal weight of xylene. Such 50-50 solution is then mixed with 1-3 volumes of water and shaken to produce an emulsion. The amount of xylene is invariably suificient to reduce even a tacky resinous product to a solution which is readily dispersible. The emulsions so produced are usually xylene-in-water emulsions (oil-i11- water type) particularly when the amount of distilled water used is. atleast slightly in excess of the volume of xylene solution and also if shaken vigorously. At times, particularly in the lowest stage of oxyalkylation, one may obtain a waterin-xylene emulsion (water-in-oil type) which is apt to reverse on more vigorous shaking and further dilution with-water.

If in doubt as to this property, comparison with a resin obtained from para-tertiary butylphenol and formaldehyde (ratio 1 part phenolthe addition of some ethylene glycol diethyletheras described elsewhere. It is understood that- Such resin, when diluted with 10 such mixture, or any other'similar mixture, is considered the equivalent of xylenefor the'pur-i pose of this test.

In many cases, there is no doubt as to the pres ence or absence of hydrophile or surface-active characteristics in the polyhydric reactants used in accordance with this invention. They dissolve ordisperse in water; and such dispersions foam readily. With borderline cases, i. e., those which show only incipient hydrophile or surface-active property (sub-surface-activity) tests for emulsifying properties or self-dispersibility are useful; The fact that a reagent is capable of producing a dispersion in water is proof that it is distinctly hydrophile. In doubtful cases, comparison can be made with the butylphenol-formaldehyde resin analog wherein 2 moles of ethylene oxide have been introduced for each phenolic nucleus.

The presence of xylene or an equivalent waterinsoluble solvent may mask the point at which a solvent-free product on mere dilution in a test tube exhibits self-emulsification. For this rea son, if it is desirable to determine the approxi mate point where self-emulsification begins, then it is better to eliminate the xylene or equivalent from a small portion of the reaction mixture and test such portion. In some cases, such xylene free resultant may show initial or-incipient 'hy-' drophile properties, whereas in presence of xylene such properties would not benoted. In other cases, the first objective indication of hydrophile properties may be the capacity of the material to emulsify an insoluble solvent such as xylene. It is to be emphasized that hydrophile properties herein referred -to are such as those exhibited by incipient self-emulsification or the presence of emulsifying properties and go through the range of homogeneous dispersibility'o'r admixture with water even in presence of added water-' insoluble solvent and minor proportions of common electrolytes as occur in oil field brines.

Elsewhere, it is pointed out that an'em'ulsification test maybe used to determine ranges of surface-activity and that such emulsification' tests employ a xylene solution. Stated another way, it is really immaterial whether a 'xylenesolution produces a sol or whether it merely produces an emulsion. i

In light of what has been said previously in regard to the variation of range of hydrophile properties, and also in light of what has been said as to the variation in the'efl'ectiveness of various alkylene oxides, and most particularly of all ethylene oxide, to introduce hydrophile charac ter, it becomes obvious that there is a .wide variation in the amount of alkylene oxide employed, as long as it is at least 2 molesper phenolic nucleus, for producing'products useful for the practice of this invention. Another variation'is the molecular size'of'the resinchain resulting from reaction between the difunctional phenol and the. aldehyde such as formaldehyde. It is well known that the size and nature or structure of the resin polymer obtained varies somewhat with the con-' ditions of reaction, the proportions .of reactants, the nature of the catalyst, etc. Based on molecular weight determinations,

most of the resins prepared as herein described,

particularly in the absence of .a secondary heating step, contain 3 to 6 or '7 phenolic nuclei with;

approximately 4 or 5% nuclei as an average.

More drastic conditions of resinification' yield resins of greater chain length. Such more in Weight, of. course, is measured bywany' suitable procedure,- particularly by cryoscopic :methods; but using the same reactants and u'sing.;more drastic conditions of 'res'inification one-usually findssthat higher molecular. weights .are indicated *:by higher melting pointsof the resins and-a tendency to decreased solubilty. See what has been; said elsewhere herein in. regard :to a sec-. ondary step involving. the heating of a resin'fwith or without the useofvacuum.

- We :have previously pointedout that. either :an a'lkalineor acid catalyst is advantageously :used in preparingthe-resin. ,A combination of-batalysts is sometimes used in two stages; for:instance, an alkaline catalyst is sometimesemployed in a first stage, .followed'by neutralization and :addition of a small amount of acid catalyst in a second :stage.- ,It is .generally believed that evenzinthe :presence of analkaline catalyst-{the number of moles of aldehyde, such as formalde hyde,-,must be greater than the molesofphenol employed in order to introduce methylol-groups in the "intermediate :stage. There is 1101 indication" that such :groups appear; in the final resin if prepared by the-usev of an acid catalyst.- It is possible that such groups may appear in-the-finished resinsprepared solely :with'analkaline catalyst; :butwe have "never been, able to confirm this fact-in 'an examination ofa large number of resins'prep'ared by ourselves. Our preference; however, is to use an acid-catalyzedresin, particu-. larly employing a iformaldehyde-to-phenol ratio of 0395, to 1.20.7and; as zfaras-wdhayebeen-able to determine, such resinsare :freefrom-methylol groups. ;At apmatter of fact, itis probable that in I acid-catalyzed resinifications; the methylol structure may-appear ronly momentarily at, the very :beginning of the'reaction and -in-all probeability is convertedat: once into a more complex structure during the intermediate stage.

One procedure which can be employed iin the use of a new resin to prepare polyhydric reactantsforuse in the preparation of compoundsemployed in the present invention, is todetermine the .hydroxylwalue by the Verley- -B6lsi-ng:method or itsequivalent: Thev resin-as such,-or in the form of a solution1- as described, is then treated with ethylene oxide in presence of -to .2-% of sodiumgmethylate as a catalyst "inJstep-Wise fashion; The conditions of reaction; as far as time or per cent are concerned,arewithin-the range previously "indicated. With suitable agitationthe' ethylene oxide, if added-in molecular proportion, combines within a comparatively short time, for instance a few-minutes (70211306 hours but in some instances requires as muchas 8 to 24*hours. A-nsefu'l temperature. range is from 125 to 225 C: Thecompletionof the reaction of each addition of ethylene :oxide in step-,- wise fashionis usually :ihclicatedbythe reduction or'elimination ofpressure. An amount conveniently used for eachaddition'is generallyequivae lent to a mole or two moles of ethylene oxidez-per hydroxyl radical. When the amount-of-ethylene oxide added is equivalent to approximately 50% by weight of the original.resim-asample istested -for incipient hydrophile properties by simply shaking up in water as is, .or after ithe'elim-inae tion of the solvent'if asolvent-is present. The amount of ethylene oxide used to obtain a usef-ul demulsifying agent as a rule varies from 70% by weight of the original resintoas much as five orsix times the weight of the original resin. In the caseof a resin .derived from;.para-tertiany butyl-phenol, as little as 5'0.%':by weight of .jethylene oxide -may give suitable solubility. With propylene :oxide, even'a'v greater molecular pro-' portion is ;required and sometimes a resultant of only limited hydrophile properties is obtainable. The same true to even a greater extent with'butylene oxide. ,The hydroxylated alkylene oxides are more effective in solubilizin properties-than the comparable compounds in which no hydroxyl is present.

Attention is directed E'to the fact thatin the subsequent examples reference :is made to the stepwise addition of the alkylene oxide, such as ethylene oxide. It! is understood, of course, there is no objection 'to the continuous addition of alkylene oxide until the desiredstage of reaction is reached. In fact-,there may'be less'of a hazard involved and it is often advantageous to 'add the alkylene oxide slowly in a continuous stream and in such amount as to avoid exceeding the higher pressures noted in'the various examples or elsewhere.

It may be well to emphasize the fact that when resins are produced from difunctional phenols and some of the higher aliphatic aldehydes, such as aoetaldehyde, the resultant-is acomparatively soft or pitch-likeresin' at ordinary temperatures. Such resins become comparatively fluid at 119 to 165 C. as a rule, and-thus can be readily 'oxyalkylated, preferably oxyethylated, without the use of a solvent.

What has been said previously is not intended to su gest that any experimentation is necessary to determine the degree oi oxyalkylation'and particularly oxyethylation. What hasbeen said previously is submitted primarily to emphasize the fact that these remarkable oxyalkylated resins'having'surface activity show unusual properties as the hydrophile character varies from a minimum to an ultimate maximum. One should not underestimate the utility of any of these poly-- hydric alcohols in a surface-active tor subsurface-active range Without examining them by reaction with a number of the typical esters herein described and subsequently examining the resultant for utility, either in demulsification or insome other art or industry as referred to elsewhere, .or as a reactant for the manufacture of more complicated derivatives. A few simple laboratory tests which can be conducted in a routine manner will usually give all the information that is required.

, For instance, a simple rule to follow isto prepare a resin having at least three phenolic nuclei and beingorganic solvent-soluble. Oxyethylate such resin, using the following four ratios of moles of ethylene oxide per phenolic unit equiva-.. lent: 2 to 1; 6 to, 1;. 10, to 1 ,and.15 to 1. From a sampleof each product remove any solvent that may be present, such as xylene. PrepareOE and 5.0% solutions in distilled water, as previously indicated. A mere examination of such series will generallyreveal an approximate range of minimumihydrophile character, moderate hydrophile character, and maximum hydrophile character. If the 2 to lratiodoes not show minimum hydrophile characterby test of the solvent-free product, then one should test its capacity to-form an emulsionwhen admixed with xylene. or other insoluble solvent. If neither test. shows the required minimum hydrophile property, repetition using. 2 to 4,molesper phenolic nucleus will serve. Moderate hydrophile character should be shown by either the 6 to 1 orlO to 1 ratio. Such moderate hydrophile character ,is indicated by 13 the fact that the sol in distilled water within the previously mentioned concentration ran'ge is a permanent translucent sol when viewed in a comparatively thin layer, for instance the depth of a test tube. Ultimate hydrophile character'is usually shown at the 15 to 1 ratio test in that adding a small amount of an insoluble solvent, for instance 5% of xylene, yields a product-which will give, at least temporarily; a transparent or translucent sol of the kind just described. The formation of a permanent foam, when a 0.5% to 5.0% aqueous solution is shaken, is an excellent.

test for surface activity. Previous reference has been made to the fact that other oxyalkylating agents may require the use of increased amounts of alkylene oxide. However, if one 'does not even care to go to the trouble of calculating molecular weights, one can simply arbitrarily prepare compounds containing ethylene oxide equivalent to about 50% to 75% by weight, for example 65% by weight, of the resin to be oxyethylated; a second example using approximately 200% to 300% by weight, and a third example using about500% to 750% by weight, to explore the range of hydrophile-hydrophobe balance. 1

A practical examination of the factor of oxyalkylation level can be made by a very simple test using a pilot plant autoclave having a capacity of about to gallons as hereinafter described. Such laboratory-prepared routine compounds can then be tested for solubility and, generallyspeaking, this is all'that is required to give a suitable variety covering the hydrophile-hy'dro-j phobe range. All these tests, as stated, are intended to be routine tests and nothing more. They are intended to teach a person, even though unskilled in oxyethylation or oxyalkylation, how to prepare in a perfectly arbitrary manner, a series of compounds illustrating thehydrophilehydrophobe range.

If one purchases a thermoplastic or fusible resin on the open market selected from a suitable number which are available, one might have to make certain determinations in order to make the quickest approach to the appropriate oxyalkylation range. For'instance, one shouldknow (a) the molecular size, indicating the number of phenolic units; (b) the nature of the aldehydic residue, which is usually CH2; and (e) the nature of the substituent, which is usually butyl, amyl, or phenyl. With such information one is in substantially the same position as if one had personally made the resin prior to oxyethylation.

For instance, the molecular Weight of the inter nal structure units of the resin of the following over-simplified formula: I Y

OH OH 0H .s F -el.

R R n R (11:1 to 13, or eyenn cre) is given approximately bythe formula; (lVIol. wt.

of phenol 2) plus mol. wt. of methylene or sub- Using one internal unit of a resin as the basic element, aresins molecular 'weightis given approximately by taking (12 plus 2) times the Weight of the internal element. Where the resin molecule has only 3 phenolicnuclei as in the structure shown, this calculation will be in" error by several per cent; but as it grows larger, to contain 6, 9, or 12 phenolic nuclei, the formula comes to be more than satisfactory. Using such an approximate weight, one need only introduce, for example, two molal'weights of ethylene oxide or slightly more, per phenolic nucleus, to produce a product of 'minimal hydrophile character. Further' oxyalkylation gives enhanced hydrophile character. Although we have prepared and tested a large number of oxyethylated products of the type described herein,-we have found no instance where the use of less than 2 moles of ethylene oxide per phenolic nucleus gave desirable products.

Examples 1b through 18b and the tables which appear in columns 51 through 56 of our said Patent 2,499,370 illustrate oxyalkylation products from resins which are useful as intermediates for producing the esterified products of the present invention, such examples giving exact and complete details for'carrying out the oxyalkylation procedure.

The resins, prior to oxyalkylation, vary from tacky, viscous liquids to hard, high-melting solids. Their color varies from a light yellow through amber, to a deep red or even almost black. In the manufacture of resins, particularly hard resins. as the reaction progresses the reaction mass frequently goes through a liquid state to a subresinous or semi-resinous state, often character-,

ized by being tacky or sticky, to a final complete resin. As the resin is subjected to oxyalkylation these same physical changes tend to take place in reverse. If one starts with a solid resin, oxyalkylation tends to make it tacky or semi-resinous and further oxyalkylation makes the tackiness disappear and changes the product to a liquid. Thusfas the resin is oxyalkylated it decreases in viscosity,- that'is, becomes more liquid or changes from a solid to a liquid, particularly when it is converted to the water-dispersible or water-soluble stage. The color of the oxyalkylated derivative is usually considerably lighter than the original product from which it is made, varying from a pale straw color to an amber or reddish amber. The viscosity usually varies from that of an oil, like castor 'oil, tothat of a thick viscous sirup. Some products are waxy. The presence of a solvent, such as 15% xylene or the like, thins the viscosity considerably and also reduces the color in dilution. No undue significance need be attached to the color for the reason that if the same compound is prepared in glass and in iron, the latter usually has somewhat darker color. If the resins are prepared as customarily employed in varnish resin manufacture, i. e., a procedure that excludes the presence of oxygen dur-' ing the resinification and subsequent-cooling of the resin, then of course the initial resin ismuch' lighter in color. We have employed some resins which initially are almost water-white and alsoyield a lighter colored final product.

Actually, in considering the ratio of aklylene oxide to add, and we have previously pointed out that this can be predetermined using laboratory tests, it is our actual preference from a practical standpoint to make tests on a small pilot plant scale. one run, and only one, and that we have a complete series'which shows the progressive effect of introducing the oxyalkylating agent, for in- Our reason for so doing is that we make stance, the ethyleneoxy :radicals. Ourpreferred p-riocedure' is as follows: We prepare a suitable resin,:or for thatmatter, purchase it in the open market. We employ =8 pounds of resin and 4. pounds of xyleneand place the resin and xylene in a suitable autoclave with an open reflux condenser. We prefer to heat andstir-until the solution-is complete. We .have pointed out that soft resinszwhich are fluidor semi-fluid can be readily prepared in'various Ways, such as the use of orthotertiary amylphenol, ortho-hydroxydiphenyl, ortho-decylphenol, or .by the use of higher molecular. rweight aldehydes .-than formaldehyde; If such resins are used, asolvent need not be added but inay be; .addedas :a ;matterof convenience or for comparison, if desired. We then add a catalystgjorrinstance, 2% of caustic'soda,in the form ore-20% to 30% solution and remove the water of solution or formation. We then shut off the reflux condenser andpuse therequipment as an autoclave only, and oxyethylate until a total of 60 pounds'of ethylene oxide have, been added, equivalent to- 750% of thegoriginal resin. We prefergatemperature of aboutl50 C. to 175 C. We-also takesamples at intermediate points as indicated in the following table:

Pounds of Ethylene Oxide Added per Percentages Spound Batch 59 some OOQOOOC 0-7 Oxytheylation to 750% can usually be completed within- 30 hours and frequently more quickly.

The samples taken are ratherpsmall, for instance,- 2to-4 ounces, so that no correction need be=made-in regard to the residual reaction mass. Each sample is divided intwo. One-half the sample is placed in an evaporating dish on the steam. bath overnight so as to eliminate the xylene. Then 1.5% solutions are prepared from bothseriesof samples, i. e., the series with xylene presentand theseries with xylene removed.

nlvljerevisual .examination of any samples in solution may be sufficient to indicate hydrophile character or surface -activity,i.-e., the product is soluble, forming a colloidal sol, or the aqueous solution foams or shows emulsifying property. All these propertie -are related through adsorption at the interface, for example, a gas-liquid interface or a liquid-liquid interface. If desired, surface activity -'can;;be measured in any one of the nisua-lways usinga Du Nouy tensiometer or dropping-pipette, or-any other procedure for measuring interfacial :tension. Such tests are conventional-and require no further description. Any: compound having sub-surface-activity, and

all derived from-thesame-resin and oxyalkylated' toa greater extent, i. e., those having agreater proportion'of alkylene oxide, are useful for the practice of this invention.

Anotherqreason why we prefer to: use a pilot plant-test of the'kind above described is that we can use the same procedure to evaluate -tolerance towards a trifunctionalphenol such as hydroxybenzene or :metacresol satisfactorily. Previous referencehas. been'rmadeztto the fact ,that ,one

can conduct a laboratory scale test which will indicatewhether or not a resin, although'ssoluble in solvent, will yield an insoluble rubbery product, i. e., a-product which is neither. hydrophile nor surface-active, upon. oxyethylation, particularly extensive oxyethylation. It is also obvious that one may have a solvent-soluble resin derived from a mixture of phenols-having present 1% or 2% of a trifunctional phenol which will result in an insoluble rubber at the ultimate-stages of oxyethylation but not inthe earlier stages. In other words,-with resins from some such phenols,addition of 2 or 3 moles of the oxyalkylating agent per phenolic nucleus, particularly ethylene oxide, gives a surface-active product which is perfectly satisfactory, 'while more extensive oxyethylation yields an insoluble rubber, thatis, an unsuitable product. Itis' obvious that this present procedure of evaluating trifunctional phenol tolerance is more suitable than the previous procedure.

It may 'berwell to callattenttion to'one result which may benotedin a long drawn-out oxyal kylation, particularly oxyethylation, which would not appear in a normally conducted reaction. Reference has been made to cross-linkingandits effect on solubility and also the fact that, if carried farv enough, it causes incipient stringiness, then pronounced stringiness, usually followed by a semi-rubbery or rubbery stage. Incipient stringinessor even pronounced stringiness, or eventhe tendency toward a-rubbery stage, is not objectionable so long-as the final product isstill hydrophile and at least-sub-surface-active. Such materialfrequen-tly is best mixed Withfi polarsolvent,such as alcohol or the like,and preferably an alcoholic solution is used. The point which we want to make here, however, is this: Stringiness or rubberizationat this stage may possibly be the result of etherification. Obviously if a difunctional phenol and an aldehyde produce a non-cross-linked resin molecule and if such moleculeis oxyalkylated so as'to introduce a plurality of hydroxyl groups in each molecule, then and in that event if subsequent etherification takesplace, one is going to obtaincross-linking in the samegeneral way-that one would obtain cross-linking in other resinification reactions. Ordinarily there is little or no tendency toward'etherification during the oxyalkylation step. If it does take place at all, it is only to an insignificant and undetectable degree. However, suppose that a certainweight of resin is treated with ,an-equal weight of or twice its weight of, ethyleneoxide. This may be done in a comparatively short time, forinstance, at or C. in 4 to 8 hours, or even less. On the other hand, if .in an exploratory reaction, such as the kind previously described, the ethylene oxide were added extremely slowly in order to take stepwise samples, so that the reaction required 4 or 5 times as long to introduce an equal amount of ethylene oxide employing the same temperature, then etherification might cause stringiness or a suggestion of rubberiness; For this reason if in-an exploratory experiment of the kind previously described there appears to be any stringiness or rubberiness, it may be wellto repeat the experiment and reach the intermediate stage of oxyalkylation as rapidly 'as possible and then proceed slowly beyond this intermediate stage. The entire purposeof this'modifiedprocedure is to cutadownithe time of reaction so as to avoid etherificatio'nif it be caused by theextended time It may be well to note one peculiar reaction sometimes noted in the course of oxyalkylation, particularly oxyethylation, of the thermoplastic resins herein described. This effect is noted in a case where a thermoplastic resin has been oxyal kylated, for instance,- oxyethylated, until it gives a perfectly clear solution, even in the presence (if some accompanying water-insoluble solvent such as to of xylene. Further oxyalkylation, particularly oxyethylation, may then yield aproduct which, instead of giving aclear solution as previously, gives a very milky solutidn suggesting that some marked change has taken place. One explanation of the above change is that the structural unit indicated in the following: way where 811 is a fairly large number, for instance, 10 to 20, decomposes and an oxyalkylatedresin representing a lower degree of oxyethyla'ti-on and a less soluble one, is generated and a cyclic poly: mer of ethylene oxide is produced, indicated thus:

This fact, of course, presents no difiiculty torn-1e reason that oXyalkylation can be conducted each instance stepwise, or at a gradual fate, and sample taken at short intervals so as to arrive at a point where optimum surface activity or hydrophile character is obtained if desired; for products for use in the practice of this inven: tiOn, this is not necessary and, in fact, may be undesirable, i. e., reduce the einciency of the product.

We do not know to what extent oxya-lkyl'ation produces uniform distribution in regard to phe nolic hydroxyls present inthe resin molecule; In some instances, of course, such distribution can not be uniform for the reason that we have not specified that the molecules of ethylene oxide. for example, be added in multiples of the units present in the resin molecule. This may be illustrated in the following mannefz' I Suppose the resin happens to have five phendlic nuclei. If a minimum of two moles of ethylene oxide per phenolic nucleus are added, this would mean an addition of 10 moles of ethylene oxide, but suppose that one added 11 moles of ethylene oxide, or 12, or 13, or 14mo1es; obviously, even assuming the most uniform distribution possible, some of the polyethyleneoxy radicals would-con tain 3 ethyleneoxy units and some would con tain 2. Therefore,- it is impossible to specify uniform distribution in regard to the entrance of the ethylene oxide or other oxyalkylating agent.- For that matter, if one were to introduce 25- moles of ethylene oxide there is no way to be certain that all chains would have 5 units; there might be some having, for example, 4 and 6 units, or for that matter 3 or '7 units. Nor is there any basis for assuming that the number of molecules of the oxyalkylating agent added to each of the mole= cules of the resin is the same, or different. Thus, where formulae are given to illustrate or depict 18 the oxyalkylated products, distributions of radicals indicated are to be statistically taken. We have, however, included specific directions and specifications in regard to the total amount of ethylene oxide, or total amount of any other oxyalkylating agent, to add.

In regard to solubility of the resins and the oxyalkylated compounds, and for that matter derivatives of the latter, the following should be noted. In oxyalkylation, any solvent emploved should be non-reactive to the alkylene oxide employed. This limitation does not apply to solvents used in cryoscopic determinations for obvious reasons. Attention is directed to the fact that various organic solvents may be employed to verify that the resin is organic solvent-soluble. Such solubility test merely characterizes the resin. The particular solvent used in such test may not be suitable for a molecular weight determination and, likewise, the solvent used in determining molecular weight may not be suitable as a solvent during oxyalkylation. For solution of the oxyalkylated compounds, or their derivatives a great variety of solvents may be employed, such as alco'hols, ether alcohols, cresols, phenols, ke'tones, esters, eta-, alone or with the addition of water. Some of these are mentioned hereafter. We prefer the use of benzene or diphenylamine as a solvent'in making cryoscopic measurements. The most satisfactory resins are those which are solublein xylene or the like, rather than those which are soluble only in some other solvent containing elements other than carbon and hydrogen, for instance, oxygen or chlorine. Such solvents are usually polar, semi-polar, or slightly polar in naturecompared with xylene, cymene, etc.

Reference tocryoscopic measurement is concerned with the use of benzene or other suitable compound asasolvent; Such method will show that conventional resins obtained, fol-example,-

from para-tertiary amylphenol and formaldehyde in presence of an acid catalyst, will have a molecular weight indicating 3, 4, 5 or somewhat greater number of structural units per molecule. If more drastic conditions of resinification are employed or if such low-stage resin is subjected to a vacuum distillation treatment as previously described, one obtains a resin of a distinctly higher molecular Weight. Any molecular weight determination used, whether cryoscopic measurement or otherwise, other than the conventional cryoscopic one employing benzene, should be checked so as to insure that it gives consistent values on such conventional resins as a control. Frequently all that is necessary to make an approximation of the molecular weight range is to make a comparison with the dimer obtained by chemical combination of two moles of the same phenol, and one mole ofthe same aldehyde under conditions to insure dimerization. As to the preparation of such dimers from substituted phenols, se carswen, Phenoiwl'astS, page 31. The increasedviscosity, resinous character, and decreased solubility, etc, of the higher polymers in comparison with the dimer, frequently are all that is required to establish that the resin contains 3 or more structural units per molecule.

Ordinarily, the oxyalkylation is carried out in autoclaves provided with agitators or stirring devices. We have found that the speed of the agitation markedly influences the time reaction. In some cases, the change from slow speed agitation, for example, in a laboratory autoclave agitation with a stirrer operating at a speed of 60 to 200 Ht P. M to high speed agitation, with the stirrer operating at 250 to 350 R. P. M., reduces the time required for oxyalkylation by about one-half to two-thirds. Frequently xylene-soluble products which give insoluble products by procedures employing comparatively slow speed agitation, give suitable hydrophile products when produced by similar procedure but with high speed agitation, as a result, we believe, of the reduction in the time required with consequent elimination or curtailment of opportunity for curing or etherization. Even if the formation of an insoluble product is not involved, it is frequently advantageous to speed up the reaction, thereby reducing production time, by increasing agitating speed. In large scale operations, we have demonstrated that economical manufacturing results from continuous oxyalkylation, that is, an operation in which the alkylene oxide is continuously fed to the reaction vessel, with high speed agitation, i. e., an agitator operating atv 258 to 359 R. P. M. Continuous oxyalkylation, other con-. ditions being the same, is more rapid than batch oxyalkylation, but the latter is ordinarily more convenient for laboratory operation.

Previous reference has been made to the fact that in preparing esters or compounds of the kind herein described, particularly adapted for demulsification of water-in-oil emulsions, and for that matter for other purposes, one should make a complete exploration of the-wide variation in hydrophobe-hydrophile balance as previously referred to. It has been stated,.further more. that this hydrophobe-hydrop'n'ile balance of the oxyalkylated resins-is imparted, as far as the range of variation goes, to a greater or lesser extent to the herein described derivatives. This means that one employing the-present invention should take the choice of the most suitable derivative selected from a number of representative compounds, thus, not only should a variety of resins be prepared exhibiting a variety of oxyalkylations, particularly oxyethylations, but also a variety of derivatives. This canbe done conveniently in light of what has been said previously. From a practical-standpoint, using pilot plant equipment, for instance, an autoclave having a capacity of approximately three to five gallons. We have made a single run by appropriate selections in which the molal ratio of resin equivalent to ethylene oxide is one to one, 1 to 5, 1 to 10, -1 to 15, and- 1 to'20. Furthermore, in making these particular runs we have used continuous addition of ethylene oxide. In the continuous addition of ethylene oxide we have employed either a cylinder of ethylene oxide without added nitrogen, provided that the pressure of the ethylene oxide was sufliciently great to pass into the autoclave, or else we have used an arrangement which, in essence, was the equivalent of an ethylene oxide cylinder'with a means for injecting nitrogen so as to force out'the eth-'- ylene oxide in the manner of an ordinary Seltzer bottle, combined with the means for either weighing the cylinder or measuring the ethylene oxide used volumetrically. Such procedure and arrangement for injecting liquids is, of course, conventional. The following data sheets exemplif such operations, i. e., the combination of both continuous agitation and taking samples so as to givefive different variants in oxyethylation. In adding ethylene oxide continuously, there is one precaution which must be taken at all times. The addition of ethylene oxide must stop immediately if there is any indication that reaction is'stopped or, obviously, if reaction is not started at the beginning of the reaction period.

Since the'addition of ethylene oxide is invariably an exothermic reaction, whether or not reaction has taken place can be judged in the usual manner by observing (a) temperature rise or drop, if any, (b) amount of cooling water or other means required to dissipate heat of reaction; thus, if there is a temperature drop without the use of cooling water or equivalent, or if there is no rise in temperature without using cooling water control,'careful investigation should be made.

In the tables immediately following, We are showing the maximum' temperature and usually theoperating temperature. In other Words, by experience we have found that if the initial reactants are raised to the indicated temperature and then if ethylene oxide is added slowly, this temperature. is maintained by cooling water vuntil the oxyethylation 'iscomplete. ,We'have also indicated the maximumpressure that we ,obtained or the pressure range. Likewise, we have indicated the time required to inject the ethylene oxide as well as a brief note as to the solubility of the product at the end of the oxyethylation period. As one period ends it will be noted we have removed part'of'the oxyethylated mass to give us derivatives, as therein describ eHY the rest has been subjected to further treatment. All this is apparent by examining the columns headed Starting mix, Mix .atiend of reaction, Mix which is removed forsample, and Mix which. remains as 'next starter.

The resins'employed are prepared-in the manner described in Examples 1a through 103a of our said-Patent 2,499,370, except that instead ofbeing preparedon a laboratory scale they were prepared in 10 to 15- a1lon electro-vapor heated synthetic resin pilot plant reactors, as manufactured by the Blaw-Knox Company, Pittsburgh, Pennsylvania, and' completely described in their Bulletin No. 2087 issued in 1947, with specific reference to Specification No. 71-3965.

For convenience, the following tables give the numbers of the examples of our said Patent 2,499,370 in which the preparation of identical resins on laboratory scale are described. It is understood that in the following examples, the change is one with respect to the size of the op-' eration.-

The solvent used in each instance was xylene. This solvent is particularly satisfactory for the reason that it can be removed readily by distillation or vacuum distillation. In these continuous experiments the speed of the stirrer in the autoclave was 250' R. P. M.

In examining'the subsequent tables it will be noted that if a comparatively small sample is taken at each stage, for instance, A to one gallon, one can proceedthrough the entire molal stage of 1 to 1, to 1 to 20, without remaking at any intermediate stage. This is illustrated .by Example 104a. In other examples we found it desirable to takea largensa'mple, for instance, a 3-gallon sample, at an intermediate stage. As aresult it was necessary in such instances to start with a new resin sample in order to prepare sufiicient oxyethylated derivatives illustrating the latter stages. Under such circumstances, of course, the earlier stages which had been previously prepared were by-passed or ignored. This is illustrated in the tables where, obviously, it shows that the starting mix was not removed froma previous-samp1e.-

Phenol for resin. Para-tertiary amylphenol Aldehyde for resin: Formaldehyde Date [Resin made in pilot plant size batch, approximately 25 pounds, corresponding to So of Patent 2,499,370 but this batch designated 10441.]

- Mix Which is Mix Which Re- Starting Mix fig f figg or Removed for mains as Next Sample Starter Max Pressure, 'lemp eraf" Solubility Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Sol- Res- 801- Res- Sol- Res- Sol- Resvent in vent in vent in vent in First Stage Resin to Et0. Molal Ratio 1:'1 14.25 15. 75 0'- 14.25 15. 75 4.0 3.35 3. 65 1.0 10.9 12.1 v 3.0 80 150 H I 7 Ex. No. 104b.

Second Stage Resin to EtO. Molal Ratio 1:5 10. 9 12.1 3.0 10.9 12. 1 -15. 3. 77 4.17 5.31 7.13 4 7.93 9. 94 70 158 $4 ST Ex. N0. 1051)..-"

Third Stage Resin to EtO Molal Ratio 1:10- 7.13 7. 93 9.94 7.13 7.93 19. 09 3. 29 3. 68 9.04 3. 84 4. 25 10.65 173 $4 FS Ex. No. 106b Fourth Stage Resin to EtO Molal Ratio 1:15. 3.34 4. 25 10. 8. 84 4. 25 16.15 2.04 2.21 8.55 1. 2.04 7.80 220 160 RB Ex. No.107b

Fifth Stage Resin to Et0 Molal Ratio 1:20- 1. 80 2.04 7. 60 1.80 2. 04 10.2 150 )6 QB Ex. No. 108b I=Insoluble. S'I=Slight tendency toward becoming soluble. FS=Fuirlysoluble. -RS=- Readily-soluble. Qs Quitesoloble.

Phenol for resin: Nonylphenol Aldehyde for resin: Formaldehyde Date [Resin made in pilot plant size batch, approximately 25 pounds, corresponding to 7012 of Patent 2,499,370 but this batch designated 109a] i Mix Which is Mix Which Re- Starting Mix figg figg of Removed for mains as Next 1 Sample Starter Max. Max. Time Pressure, Temp erahrs Solubility I b s. gbs. Lbs Ibls. Ifibs. Lbs 1 .1. 5. I bs. Lbs 1.11 s. gas. Lbs

o es: o eso es- So esvent in Eto vent in Eto vent in Eto vent in Eto First Stage Resin to EtO. I Molal Ratio 1:1 15.0 15.0 0 15.0 15.0 3 5.0 5.0 1.0 10. 0 10.0 2.0 50 150 1% ST Ex. No. 10917.

Second Stage Resinto EtO Molal Ratio 1:5 1O 10 2.0 10 10 9.4 2. 72 2. 72 2. 56 7. 27 7. 27 6. 86 100 147 2 D'I Ex. No.

Third Stage Resin to EtO. M0181 Ratio 1:10. 7. 27 7. 27 6. 86 7. 27 7. 27 13. 7 4.16 4.15 7. 68 3.15 3.15 5. 95 1% S Ex. N0. 111b Fourth Stage Resinto EtO i Molal Ratio 1:15.. 3.15 3.15 5. 95 3.15 3.15 8. 95 1.05 1.05 2. 95 2.10 2.10 6. 00 220 174 2% S Ex. No. 1120- Fifth Stage Resin to moi.-- Molal Ratio 1:20 2. 10 2. 10 6. 00 2.10 2. 10 8.00 220 183 35 VS Ex.'No. 1I3b' S Soluble. ST Slight tendency toward solubility. D1 Definite tendency toward solubility. VS Very soluble.

Phenol for resin: Paraoctylphenol Aldehyde for resin: Formaldehyde.

Date

[Rosin made in pilot plant size batch, approximately 25 pounds, corresponding to So of Patent 2,499,370 but this batch designated 1140.]

Mix Which 1.. Mix Which Re- Starting Mix figg figg of Removed for mains as Next Sample Starter V Max. Max. Time Pressure, 'Iemperah q Solubility lbs. sq. in. ture, C. Lbls. abs. Lbg abs. Lbs Lbis. abs. Ifibs. Lbs So eso es- So eso esvent in Eto vent in L vent in Eto vent in Eto First Stage Resin to EtO. Moial Ratio 1:1 14.2 15.8 14. 2 -15. 8 3. I 3.1 3.4 0.75 11. 1 12.4 2. 5 150 1H2 NS Ex. No. 1145.

Second Stage Resin to EtO v MolalRatio 1:5 11.1 12. 4 2.5 11.1 12. 4 12. 5 7.0 7. 82 7. 88 4.1 4. 58 4. 62 100 171 H SS Ex. No. 1150...

Third Stage Resin to 15120.... M01211 Ratio 1:10. 6. 64 7. 36 0 6. 64 7.36 15. 0 120 190 1% 8 Ex. N0. 1160.

Fourth Stage I Resin to EtO.-. Molal Ratio 1:15-. 4.40 4. 9 0 4. 4 4. 9 14. 8 400 160 )4 VB Ex. No. 1175.

Fifth Stage Resin to Et0 Molal Ratio 1:20.. 4.1 4. 58 4.6 4. i 4. 58 18. 52 260 172 )4 VS Ex. No. 11812"-.-

S=Bolub1e. NS=Not soluble. SS= Somewhat soluble. VS=Very soluble.

Phenol for resin: Menthylphenol Aldehyde for resin: Formaldehyde Date [Resin made in pilot plant size batch, approximately 25 pounds, corresponding to 69a of Patent 2,499,370 but this batch designated 1190.]

Mix Which is Mix Which Re- Starting Mix fig'g gg of Removed for mains as Next Sample Starter Max. Max. Time I Pressure, Temp atahrs Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. 801- Res- $1 801- Res- Egg Sol- Resg Sol- Res- 3 vent in vent in vent in vent in First Stage Resin to EtO.

13. 65 16. 35 0 13. 65 16. 36 3. 0 9. 11. 45 2. 1 4. 1 4. 9 0. 9 150 1% NS Ex. No. 11911.

Second Stage Resin to EtO. Molal Ratio 1: 10 12 0 10 12 10. 4. 52 5.42 4.81 5. 43 6. 58 5.94 1%: 8 Ex. No. 1Z0b- Third Stage Resin to EtO- Molal Ratio 1:10.- 5.48 6.58 5.94 5.48 6. 58 10.85 90 100 K 8 Ex. No. 1215.....

Fourth Stage Resin to EtO-. Molal Ratio 1:15-- 4. 1 4. 9 0.9 4. 1 4. 9 13. 15 180 171 1%: VS Ex. No. 1221;"...

Fifth Stage Resin to Et0-- Molal Ratio 1:20-- 3. 10 3. 72 0. 68 3. 10 3. 72 13. 43 320 $4 VS Ex. No. 123a..."

S=Solubie. N S==Not soluble. VS=Very soluble.

I as .Aldehyde for resin: Formaldehyde Date [Resin made in pilot plant size hatch, approximately 25 pounds, corresponding to 2a of Patent 2,499,370 but this batch designated 12411.]

. Mix Which is Mix Which Re- Starting Mix fi E 3 of Removeclfor mains as Next 0 Sample Starter Max. Max. Time Pressure, Tem erar hm Solubility Lbs. Lbs. Lb; Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Sol- Res- Sol- Res- 801- Res- Sol- Resvent in vent in vent in vent in Firsi Stage Resin to EtO M0181 Ratio 1:1" 14.45 15. 0 14. 45 15.55 4. 25 5. 97 6.38 1. 75 8. 48 9.17 2. 5O 150 9i: NS Ex. No. 124b Second Stage Resin to EtO Molal Ratio 1:5 8. 48 9. 17 2. 50 8. 48 9. 17 16. 0 '5. 83 6. 32 11. 05 2. 2. 85 4. 95 188 35 SS Ex. No. b

Third Stage Resin to Et0. Mola1Ratio1:10 4.82 5.18 0 4.82 5.18 14.25 .0. 400 183 $6 3 Ex. N0. 126b Fourth Stage Resin to EtO M01111 Ratio 1:15- 3. 85 4. 15 0 3. 85 4.15 17.0 120 180 $6 VS Ex. N0. 1275...

Fifth Stage Resin to EtO Molal Ratio 1:20 2.65 2.85 4.95 2.65 2.85 15.45 80 170 9'1: VS Ex. No. 128b S=S0luble. NS=Not soluble. SB=Somewhat soluble. Y vs vr sbluble.

Phenol for resin: Menthyl Aldehyde for resin.- Propionaldehyde Date [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to file of Patent 2,499,370 but this batch designated 12911.]

Mix Which is Mix Which Re- Starting Mix figs fi g of Removed for mains as Next Sample Starter Max. Max. Time Pressure, Temgerahrs. Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. turer Lbs. Lbs. Lbs. Lbs. Sol- Res- Eto Sol- Res- Eto Sol- Res- Eto Sol- Res- Eto vent in vent in vent in vent in First Stage I Resin to Et0 Molal Rati01:l 12.8 17.2 12. 8 17.2 2. 75 4. 25 5.7 0. 95 8.55 11.50 1.80 110 $5 Net soluble. Ex. No. 129b Second Stage Resin to EtO Molal Ratio 1:5.-- 8.55 11.50 1.80 8. 55 11. 50 9.3 4. 78 6. 42 5.2 3. 77 5.08 4.10 100 }6 Somewhat Ex. No. 1301).... soluble.

Third Stage Resin to EtO Molal Ratio 1:10 3. 77 5.08 4.10 3. 77 5.08 13.1 100 182 $4: Soluble. Ex. No. 131b Foanfh Stage Resin to 13170.... Molal Ratio 1:15-. 5. 2 7.0 5.2 7. 0 17. 0 2. 10 2.83 6. 87 200 182 34 very soluble. Ex. No. 132b Fifth Stage Resin to EtO Molal Bati01:20 2. 10 2.83 6.87 2. 10 2.83 9.12 90 150 )6 Do. Ex. N0.133b--- Phenol for resin: Para-tertiary amylphenol Aldehyde for resin: 'Furfural Date [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 42a of Patent 2,499,370 but this batch designated as 13401.]

Mix Which is Mix Which Re- Starting Mix ggg figg of Removed [or mains as Next Sample Starter l'rgressure, lemp era- 32 Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Sol- Res- Sol- Res- Sol- Res- Sol- Resvent in vent in vent in vent in First Stage Resin to EtO- Molal Ratio 1:1..- 11. 2 18.0 11. 2 18. 3. 5 2. 75 4.4 0.85 8.45 13.6 2. 65 120 135 1% Not soluble. Ex. No. 13 1b...

Second Stage Resin to EtO. Molal Ratio 1:5 8. 45 13. 6 2. 05 8.45 13.6 12. 65 5. 03 8. 12 7.55 3.42 5.48 5. 110 150 M Somewhat Ex. No. 135b. soluble.

Third Stage Resin to Et0. Molal Ratio 1:10. 4. 5 8.0 4. 5 8.0 14. 5 2. 4.35 7.99 2.05 3. 65 0. 180 163 Ma Soluble. Ex. No. 13Gb-.. 7

Fourth Stage Resin to EtO Molal Ratio 1:15 3. 42 5. 48 5. 10 3.42 5.48 15. 180 188 36 Very soluble. Ex. N0. 1375.. r

Fifth Stage Resin to EtO. Molal Ratio 1:20 2.05 3.65 6. 60 2.05 3. 13. 35 120 125 34; D0. Ex. No. 13812.....

Phenol for resin: Menthyl Aldehyde for rain: Furfural Date [Resin made on pilot size batch, approximately 25 pounds, corresponding to 8911 of Patent 2,499,370 but this batch designated as 13%;]

- Mix Which is Mix Which Re- Starting Mix figggg of Removed for mains as Next Sample Starter Max Max llgressure, gemp elgi Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs

Lbs. 'Lbs. Lbs. Lbs. 801- Has Sol- Res- 801- Res- Sol- Resvent in Eto vent in Eto vent in Eto vent in Eto First Stage Resin to E tO Molal Ratio 1:1 10. 25 17. 10.25 17. 75 2.5 2. 65 4. 60 0. 55 7. 6 13.15 1.85 90 150 16 Not Ex. No. 1395. soluble.

Second Stage Resin to Eton Molal Ratio 1:5-. 7. 6 13. 15 1. 7. 6 13. 15 9.35 5. 2 9.00 6. 40 2.4 4. 15 2.95 80 177 }6 Somewhat Ex. No. 1405. soluble.

Third Stage 0a aio 4.22 6.98 4.22 6.98 10.0 1 lubl Ex. N0. 1411)... 65 so a Fourth Stage 112 5 1 11 t 3 7 0a a i0 :15. 6 6.24 3.70 6.24 13.25 1 V Ex. No. 1425-.-" 71 56 5013510.

Fifth Stage b en 0a a 0 220.- 2.4 4.15 2.95 2.4 4.15 11.70 D Ex. No. 143b 90 O 2,581,377 29 30 Phe nol'for'resin: 'Para-octyl Aldehyde! resim FurfumZ Date [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 42a of Patent 2,499,370 with 206 parts by weight of commercial para octylphenoi replacing 164 parts by weight of para-tertiary amylphenol but this batch designated as 14441.]

. Mix Which is Mix Which Re Starting Mix fi 2 Removed for mains as N ext Sample Starter Max v Pressure, '1emp era- EE? Solubility Ibls. Ifibs. Lbs 1 11 5. gbs. Lbs lbls. 05. Lbs lslbls. libs. Lbs

o eso eso eso esvent in Eto vent in vent in Eto vent in m0 First Stage ResintoEtO Molal Ratio 1: 12 1 18.6 12.1 18.6 3.0 5.38 8. 28 1.34 6. 72 10.32 1. 66 80 150 M2 Insoluble. Ex. No. 144b Second Stage I Slight tend- Resin to EtO. enny to"- Moial Ratio 1:5-.- 9 14. 25 9.25 14. 25 11.0 3. 73 5.73 4.44 5. 62 8.52 6.56 100 177 942 ward bB- Ex.No. 1 15b"-.. coming soluble. Third Stage 7 Resinto EtO- Molal Ratio 1:10.- 6 72 10. 32 1. 66 6. 72 10. 32 14. 91 4. 97 7.62 11. 01 1. 75 2. 3. 90 85 182 Fairly solu- Ex. No. 146b. ble.

Fourth Stage Resinto EtO I Mo1a1Batio1:15. 5 52 8.62 6. 58 5. 52 8.52 19. 81 100 176 $6 Readilysolu- Ex. N0. 1476"..- ble.

Fifth Stage Resin to Et0. i Molal Ratio 1:20. 1. 2. 70 3. 90 1. 75 2. 70 8. 4 160 M Quite solu- EX. No. 1481)."... V ble. v

Phmol forreain: Para-phenyl Aldehudajot resin: ,Furfaral v i Date I [Resin made on pilot 31am size batch, approximately 25 pounds, correspondingto 42a 0! Patent 2,499,370 with 170 par ts by weight at commercial parap enylphenoi replacing 161 parts by weight'of para-tertiary amylphenol but this batch designated as 14%.]

. Mix Which is Mix Which Re- Starting Mix fi 3 Removsd for mains as N ext Sampiu Starter Max. Max. Time xlgressure, gemp erahrs Solubility Lbs. Lbs. Lb s. Lbs. Lbs. Lbs. Lbs. Lbs. 39* s01- Res- E53- S01- Res- $5- 801- Resg2? s 1- Resgeavent in vent in vent in vent in First Stage Resin to 15130.... Molal Ratio 1:1-. 13 0 16.7 13.9 16.7 3.0 3.50 4.25 0.80 10.35 12. 45 2.20 100 160 M; Insoluble. Ex. No. 149b I Second Stage Blight tend- Resinto Et0, enc to- Molal Ratio 1:5-.- 10.35 12. 45 2.20 10.35 '12. 45 12.20 5.15 6.19 6. 06 5. 20 6.26 0.14 80 183 war solu- Ex. No. 150b Third Stage 8.90 10.7 8 10.70 '19. 0 5:30 6.38 11. 32 3.60 4.32- 7.68 90 193 K: Fig-1y solue. Fourth Stage Resin to EtO I I Molal 3813101415.. 5 20 6. 26 6.14 5. 20 6.26 16.64 171 i $6 Readily B01- Ex. No. 1525..... ubl'e;

Fifth Stage Resin to Et0...

Sample somewhat rubbery and. gelat- 1t1a l1a1tgg 1..2 0:} a 60 4.32 7.68 3.60 4.32 15.es{ I mousl but ffimy soluble l 230 2 Phenol for resin-z.Para-nonglphenol Aldehyde for resin: Furfural Date '[Resin made on pilot plant size batch, approximately pounds, corresponding to 88: oi Patent 2,499,370 but this baton designated as 15411.]

Mii Which is Mix Which Rs- Starting Mix f gg gg Removed for mains as Next Sample Starter Max. Max. ime Pressure, Temp erahm Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Sol- Res- 501- Has Sol- Res- Soi- Resvent in vent in vent in vent in First Stage Resin to EtO- Molal Ratiolzl--- 10. 20. 75 10.85 20. 75 3.0 2. 57 4.90 0. 73 8.28 15.85 2. 27 Insoluble. Ex. No. 1545.....

Second Stage Slight Resin to Et0.-.. tendency Moial Rstio1:5- 8 28 15. 85 2. 27 8. 28 15. 85 11. 77 3. 82 7.33 5. 45 4. 40 8. 52 6. 32 100 182 16 toward Ex. No. b. I becoming soluble.

Third Stage Resin to EtO. Moial Ratio1:10- 5 95 11.35 5. 95 11.35 16. 75 3. 38 6.42 9. 50 2. 57 4.93 7.25 100 181 $6 Fflirly Ex. No. 156b.--.. soluble.

Fourth Stage Resin to Et0 Molal Ratio1:15-- 4.46 8. 52 6.32 4.46 8. 52 19.07 90 188 $6 Readily v Ex. No. 1575..... soluble.

Filth Stage Resin to EtO..-. Molsl Ratiol 2 57 4. 93 7. 25 2. 57 4. 93 14.50 100 Quite Ex No. 168h.. soluble.

Phenol for resin 'Pafa-phenylphen'ol Aldehyde for resin. Formaldehyde Date - [Rsin made on pilot plant size batch, apiroximat'eiy 25 pounds, corresponding to 9a ot Patent 2,499,370 but this batch designated as 159a.)

Mix Which is Mix Which Re- Starting Mix fig fi g or Removed for mains as Next Sample Starter Max. Max. Time Pressure, Temp erw hrs Solubility 1811); gas. Lbs gb a. abs. Lbs gb Ifibs. Lbs r b s. Ifibs. Lbs

oes- 0- es- 0- es- 0- esvent in Etc vent in Eto vent in Eto vent in Eto First Stage Resin to EtO-. Molal Ratio 1'1 Ex. No

Second Stage Resin to EtO.--- .Molal Ratio 1:5.-. 11. 0 9.0 11.0 9.0 11. 75 7.6- 6.2 8.11 3. 41 2.80 3. 64 160 188 $4 Insoluble.

Ex. N0. 159b Third Stage Resinto Et0. Moial Ratio1:10 Ex. No

Fourth Stage Resin to 10120.... Molal Ratio 1:15-. e Ex. N o

Fifth Stage Resin t0 EtO- M0181 Ratio 1:20.- 3 41 2. 80 3.64 3. 41 2.80 13.64 80 170 M Soluble. EX. No. 1600-.-...

Date

[Resin made on pilot plant size batch, approximately 25 pound para-secondary butylphenol'replaeing 1 Phenol for resin: Para-.t"e'comim-y butglphenol 34 Aldhydefor resin: Furfm-al Mix whims. Mix-Whieh'Re- Starting Mix ggs figg' Removed for mains as Next Sample Starter Max. Max. Time Pressure, Temp erahm Solubility Lbs. Lbs. Lbs. Lbs. Lbs. 1am. Lbs. Lbs. Sol- Res- Sol- Res- Sol Res- S Resvent in vent in vent in i wentin First Stage Resin t'o' Et0 I I Molal Ratio 1 12.0 17. 9 12.0 17.9 3. 5 2. 65 3. 98 0. 77 9. 35 13. 92 2. 73 150 171 $6 Insoluble. Ex. N0. 161)).

Second Stage I Slight tend- Resinto'EtO.... i ency to- Molal Ratio 1. 13. 92 Q. 73 9. 35 13. 92 13. 23 5. 00 7. 42 7. 081 4. 35 6.50 6.15 100 192 M; Ward be- Ex. No. 16Gb"... comingsoluble. Third Stage Resinto EtO. Molal Ratio 1:10. 6. 8. 95 6. 25 8. 95 17.0 3.23 4. 61 8. 76 3.02 4.34 8. 24 120 188 542 Fairly solu- EX. N0. 163b ble.

Fourth Stage Resin to Et0 M0131 Ratio 1:15. 4. 6. 6. 15 4. 35 6. 50 18. 40 100 181 k; Readily 501- EX. No. 16 1b--. uble.

Fifth Stage Resin to EtO. Sample somewhat rubbery and gelat- Molal Ratio 1:20- 3.02 4. 34 8. 24 3.02 4.34 16.49 inous but shows. limited water sol- 120 161 EX. No. 165bv ubility.

I I I I Phenol for resin: Para-octylphenol Aldehyde for resin: Propz'onaldehyde Date [Resin made on pilot plant size batch, approximately 25 pounds, eorres para-octylphenol replacing 164 parts'b pending to 34a of Patent 2,499,370 with 206 parts by weight of commercial '37 weight of para-tertiary amylphenol but this batch designated as.166a.]

. 7 Mix- Which is Mix Which Re- Starting Mix 3: 2;? of Removed for mains as Next Sample Stant'er Max. Max. Time Pressuqe; 'Iemp erahrs Solubility i b s. r bs. Lbs lbls; libs. Lbs 11 s. gbs. Lbs 1 13 5. LRbs. Lbs ture,

0 eS- o eso es- 0 esvent in Eto vent in Eto vent in Eto vent in Eto First Stage Resin to EtO v Molal Ratio 1:1 13. 3 16. 9 13.3 16. 9 3. 0 3. 1 4. 0 0. 10. 2 L 12. 9 2.3 100 150 Insoluble. Ex. No.166b i g Second Stage I 5 Resin to mom. i I i g g I Molal Rati01z5... 10.2 12.9 2.3 10.2 12.9 vf11.3 6.34; 8.033 7.03; 3.86; 4.87: 4.27f 100 166 34 Becoming Ex. No. 167i)..... 5 i f soluble.

Third Stage I j Resin to EtO f 1 I E Molal Ratio L113. 6. 46 8. 24 6. 46 8. 24 16. 5 3 3. 52 I 4.49 t 8. 99 2. 94 3. 7. 51 177 $4 Fairly Solu- Ex. No. l68b I g j 1 ble.

Fourth Stage j Resin to EtO i i Molal Ratio 1:15.. 3.86 4.87 4.27 3.86J 1.87. 13.02 80 204 M Readily sol- Ex. N0. 1692). uble.

Fifth Slage Resin to Et0.. I M01211 Ratio 1 :20 2. 9-1 3. 75 7. 51 2. 94 3. 75 13. 26 14 Soluble. Ex. No. b.

3. 3 '36 Phenolfor-resin: Para-nonylphenol Aldehyde for resin: Propionaldehyde Date [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 82a of Patent 2,499,370 but this batch designated as 171a,]

- Mix Which is Mix Which Re- Starting Mix fi 25 1 3 or Removed for mains as Next Sample Starter Max. Max. Time nrgressure, Iemgelghrs Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Sol- Res- Sol- Res- Sol- Res- Sol- Resvent in vent in vent in vent in First Stage Resin to EtO.. Molal Ratio 1:1... 10.9 18.0 10.9 18.0 3.0 2.65 4.4 0.75 8.25 13.60 2.25 120 150 M2 Insoluble. Ex No. 1m... I

Second Stage Resin to EtO. Mo1a1.Ratio1:5 8.25 13. 60 2.25 8.25 13. 00 11.50 5.10 8. 7.05 3.16 6.25 4. 95 174 36 Becoming Ex. No. 1720. r soluble.

Third Stage Resin to Et0.... Molal Ratio 1:10.. 5.65 9.35 5.65 9.35 15.75 3.71 6.14 10.35 1.94 3.21 5.40 90 182 M2 Fairly Ex. No. 173b soluble.

Fourth Stage Resin to EtO. Molal Ratio 1:15.. 3.15 5.25 4.45 3.15 5.25 13.45 182 $45 Readily Ex. No. 1741:. soluble.

Fifth Stage Resin to EtO. MolalRatio 1:20-. 1. 94 3. 21 5. 40 1. 94 ,3. 21 10. 65 150 96 Soluble. Ex. No. 1755..... 1

Phenol for resin: Para-tertiary amylphenol Aldehyde for resin: Propionaldehyde Date [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 34a of Patent 2,499,370 but this batch designated as176a.]

Mix Which is Mix Which Re- Starting Mix figg figg of Removed for mains as Next Sample Starter Max. Max. Time 1ItJressure, 'gemp ezgms Solubility Lbs Lbs Lbs Lbs Lbs Lbs Lbs Lbs Lbs. Lbs Lbs Lbs S01- Res- 801- Res- Sol- Res- Sol- Resvent in E150 vent in Eto vent in Eto vent in Eto First Stage Resin to EtO Molal Ratio 121... 12.6 16.2 12.6 10.2 3.5 3. 08 3.96 0.80 9.52 12.24 2.64 M2 Insoluble. Ex. N0. 1760..."

Second Stage Resin to EtO. Molal Ratio 1:5 9.52 12.24 2.64 9.52 12.24 12. 89 5.27 6. 79 7.14 4.25 5.45 6.75 85 171 6 Becoming Ex. No. 1775.-." soluble.

Third Stage 6.5 8.3 6. 5 8.3 17.75 3.81 4.87 10.42 2. 69 3.43 7.33 120 183 5% Fobifly solu- 4.25 5.45 5.75 4.25 5.45 17.25 85 106 P6 Readily soluble.

} 2.69 3.43 7.33 2.69 3.43 14.55 95 $5 Soluble.

means duce 'soap: orisoapelike rmaterials, and rare: the: ob-

vious equivalent of .theunchange'd ormnmodified detergent-forming acids. 1 For instance, instead of fatty acids, one: might-employs the-chlorinated fattyzacids. Instead of the resimaci'ds, onecmight employ the hydrogenated :resin acids. Instead of naphthenic acids, one -might'employ brominatednaphthenic acids-etc.

The fatty acids are of: the type commonly re- 'ferredto as higher fatty acids; and, or -course,

this is also true inregard-to derivatives of the kind indicated insofar that .such derivatives are obtained irom'higher'fatty acids. I he petroleum acids include not only naturally-occurring 'naphthenic acids, -but also acids obtained-by the oxidation of'wax, parafiin,=etc. Such-acidsinay have-as-many as 32 carbon atoms. -'-For' instance, see U. S. Patent No. 2,2423837- dated Iviay"20," l 9 ll, to Shields.

lhe monocarboxy detergent-forming esters of the'oxyalkylated derivatives-herein described are preferably derived-from unsaturated :fatty "acids :havingtlBcarbon atoms. Such unsaturated-fatty acids include -oleic acid, ricinoleic .acidjrlinoleic acid, linolenic' acid, :etc. One may employ mixed fatty acids, "as for "example, the fatty acids "jobtained from hydrolysis of cottonseed oil, "soyabean oil, etc. Itis our ultimate preference' that the esters of 'theikindiherein contemplatedbe "derived from unsaturated fatty acids, and more especially, unsaturated fatty acids containing :a hydroxyl radical, or unsaturated .fatty acids which have been subjected to oxidation. I n addition to synthetic carboxy acids obtainedby the oxidation of parafiins or the like, there is the somewhat analogous classsobtainediby treating carbon dioxide or carbon monoxide,- in the presenceof hydrogen-or an=olefin,'-.with. steam, or by causing. a halogenated hydrocarbon to reactwith potassium cyanide and sapcnitying the :product obtained. Such products or mixtures :thereof, having at least8 and notmore than v32 carbon atoms and having at least one carboxylagroupwor the. equivalent thereof, are.suitableasdetergentforming .monocarboxy: acids; :and another analogous class actuallysuitableisthe mixture o'i carboxylic acids obtained by'the alkali treatment of alcohols of high molecular .weight formed in :the catalytic hydrogenation of :carbon: monoxide.

As is .well known, one ,need *not :use the high molal carboxy acid, \such ;as a fattyacid, for introduction of the; acyl. group of xacyloxy group. Any suitable functional .4 equivalent such as the acyl halide, the-anhydride; ester, amide, etc, may be employed.

Previous reference has been made to the .fact that the present invention .is concerned with mixed esters which areparticularly adapted .for use as demulsifiers. These esters, referred to-as mixed esters insofar that they contain the acyl radicals of two different car-boxy aclds,;may-.be total or partial esters. Immediately ,preceding there has been described :one -..type of acid1employediin 1 the manuiactureeofr'the :mixed sBSliBlfS.

This type of acid is the high molalumonoca-rboxy detergent formingeacid. zAnotherwtyperof: acid is an; alpha halogen :.monocarboxylic acid 'having .not over':6.carbon...atoms. 'I-'ypica1 acidatexemplifying this class care .ichloroacetic, 'dichloroacetic, bromoacetic, ..-'alpha :bromcbutyric, aetc.

'Needless to' say that OUI DI'GfBIGIlCQiS toemploy either theacidsthemselves: or the acylchlori'des. It is our preference-tense: chloroacetic acid for the reason 'that' it is'cheap and particularly reactive. Chloroacetyl chloridei'is a pre"ferred=reactant from the standpoint of =1'eactivity *but==-is objectionable for two reasons, -one being that eliminating hydrochloric acid in -=the reaction there'isa tendencycause corrosion ofrthe :ap-

"paratus; unless-especially I designed,=and'-secon'dly, 'this reactant is comparatively expensive. llow ever, except for" these two objections itmay -be considered as a preferred-"reactant. Our preference is to use any alpha-halogen--carboxylic acid if not over'--'6='carbon-- atoms. Other suitable acids" include alpha-chloropropienic acid, alphachlorobutyric acid, alpha-bromoisocaproic acid, bromoacetic acid; iodoacetic acid, etc. The acyl halidesor anhydrides of these acids, of course, may be employed. In=many instancesthe alphahalogenated acylchloride is as "IBBJd'ijlY' available as the-alpha-halogen -acid. "Ihereason-for this is the fact that it is difficult to halogenate "an acid seas-to introduce the ha-lgen 'in an alpha position, but an acyl halide reacts more rapidly and-"the halogenenters the'-alpha -positionidue'toithe-negative elfect 'of looth'the ichlorine atom and the carbonyl atom. Under.such-circumstanceswhere the alpha-'chloroacyl acid' is availablefthere is no reason, of course;to hydrolyzean acyl chloride to the'acid in orderto useithe acidinstead.

There are -a'number-of obvious waysjfonmanufacturing mixed esters and some of "the simpler methods are asfollows: .(a) Prepare a partial ester from a high molal'detergent-for ning monocarboxy acid "as described and'then reactfurther with chloroacetic'acid QrLtheJIike; (b) preparea complete or 1 partial ester from "a hydroxylated high molalxmonoca'rboxy ,acid, such asiricinoleic acid, hydroxystearic acid, chlorinated ricinoleic acid, dihydroxystearic acid, ,etc., and then "subjectto further actionoi chloroacetic acid, .orthe like. This method canbe'applied to complete esterssince the acyl radical includes at least one hydroxyl radical; (c) prepare a partial ester "from chloroacetic acid, bromoacetic acid, fdichloroacetic acid, or the like,.an'd then react further with a high molal monocarboxyiacid asgdescribed; and. (d) produce anesterbyithe simultaneous-use of .bothtypes of acid,.i. :e.,..react simultaneously with chloroacetic :acid -or .thelike .on the one hand, and a high molal. monocarboxy. detergentforming .acid on the other Thand.

The following examples -areincluded-to illustrate these procedures.

Example -1c In the procedure employed inthemanufacture ofthe instant product one starts with a partial ester of .a high molal detergent-forming monocarboxy acid. These-estersare described: in'complete detail in our two co pendingapplications, Serial Nos. 64,454 and 64,455,.both; filed December 10, 1948, of which the former has .maturedinto Patent No. 2,541,995 and the latter intol-Eatent No. 2,542,000 both-10f =which lissuedi'li'ebruary 330, 195.1. .lReierencejisixnadei-to.thesexoependinglaw .plications for further examples of suitable starting materials.

An oxyalkylated derivative, such as Example 1b, preceding, was esterified with oleic acid in an amount sufiicient to convert approximately one-fourth of the polyglycol radicals into the fatty acid ester. The hydroxyl value of the oxyalkylated derivative can be calculated without determination, based on the hydroxyl value and weight of the phenol-aldehyde resin originally employed, plus the increase in weight after oxyalkylation. If glycide or methylglycide is employed, allowance must be made for the polyhydric character of the oxyalkylating reactant. In any event, if desired, the hydroxyl value of the oxyalkylated product can be determined by the Verley-Bdlsing method, or any other acceptable procedure. The esterification reaction is conducted in any conventional manner, such as that employed for the preparation of the higher fatty acid esters of phenoxyethanol.

Fatty acids, and particularly unsaturated fatty acids, show at least some solubility in the oxyalkylated derivatives of the kind shown in the previous examples, even though this is not necessarily true of the glycerides of the fatty acids. In this instance reference is made to the oxyalkylated derivatives in absence of a solvent. Since esterification is best conducted in a system, it is our preference to add xylene, or even a higher boiling solvent such as mesitylene, cymene, tetralin or the like, and conduct esterification in such consolute mixture. It is not necessary to add all the fatty acid at one time. One may add a quarter or half the total amount to be esterified, and after such portion of the reactant has combined then add more of the fatty acid. The solubility of the fatty acid, of course, increases as the hydroxyl radical is replaced by an ester radical. This is also true if one resorts to transesterification or cross-esterification with the glyceride or low molal alcohol ester.

Our preference is to have present a substantial amount of xylene or higher boiling water-insoluble solvent, and to distill under a reflux condenser arrangement so that water resulting from esterification is volatilized and condensed along with the xylene vapor in a suitably arranged trap. The amount of xylene employed is approximately equal to one-half the weight of the mixed reactants. The water should be removed from the trap, either manually or automatically, and the xylene returned continuously for further distillation. Such reaction is hastened if a small amount of dry hydrochloric acid gas is continuously injected into the esterification mixture.

The procedure employed in the instant experiment produces a partial ester, i. e., an ester having residual alcoholic hydroxyl radicals. The same prccdure, of course, may be employed to produce a complete or total ester, including one from ricinoleic acid or the like. A complete ester in this instance yields a material susceptible to further reaction with chloroacetic acid or the like. A sulfonic acid, such as toluene sulfonic acid, may be added in amounts of to 1% to act as a catalyst.

As a specific example, 900 grams of the xylenecontaining oxyalkylated resin 121i) were reacted with 70.6 grams of oleic acid in the presence of 300 grams of additional xylene and grams of toluene sulfonic acid. Refluxing was continued for 3 hours 01' until 4.5 grams of water were evolved.

Starting with a partial ester of the kind described, for. example, 643 grams orthe starting 40 material described immediately preceding, there was added 23.6 grams of chloroacetic acid and the product refluxed for 3 hours at 140 to 145 0., until approximately 4.5 grams of water were separated. The resultant product represented a xylene solution of the mixed ester. If desired, the xylene can be removed by distillation, particularly vacuum distillation. The product was amber in color and showed fair dispersibility in a water.

Example 20 The same procedure was followed as in Example 1c, preceding, the initial step being to produce the particular ester from the high molal monocarboxy acid. Thus, the procedure Was varied in that more oleic acid was employed so that the residual hydroxyls left represented a lower percentage. As a specific example 854 grams of the xylene-containing oxyalkylated resin 11Gb were reacted with 141.2 grams of oleic acid in the presence of 200 grams of additional xylene and 15 grams of para-toluene sulfonic acid at 140 C., until 9 grams of water were evolved, usually about 4 hours. 600 grams of the product obtained in the manner described above were used for further reaction with 22 grams of chloroacetic acid. The mixture was refluxed for 5 hours at 143 C. until 4.4 grams of water were collected in the water trap.

Example The same procedure was followed as in Example 1c, preceding, 1. e., a partial ester was first produced from a high molal monocarboxy acid. 300 grams of xylene-containing oxyethylated resin identified as 1172) were employed for reaction with the oleic acid. This solution contained 54.6 grams of xylene. The amount of linoleic acid employed was grams. To the mixture there were added 200 grams-of additional xylene and 20 grams of para-toluene sulfonic acid and 11 grams of chloroacetic acid. The mixture was refluxed for 6 /2 hours at 152 until 4 /2 grams of water had been driven out, to wit, a total of 9 grams.

Example 40 The same procedure was followed as in Example 1c. The starting material was a partial ester derived from a high molal monocarboxy acid. 300 grams of the xylene-containing resin identified as 107b, were reacted with stearic acid. This resin solution contained 47.8 grams of xylene. The amount of stearic acid employed was 30 grams, along with 200 grams of added xylene and 20 grams of para-toluene sulfonic acid. When the reaction was complete about 2 grams of water had been driven out. The time required was about 4.4 hours and the temperature of reflux about 147 C. 15.2 grams of bromoacetic acid were then added and the refluxing continued for another 4 /2 hours, until approximately 4 grams or slightly over 4 grams, of water had been driven out; that is, total water eliminated during the formation of the mixed ester was slightly in excess of 6 grams.

Example 

1. A MIXED ESTER IN WHICH THE ACYL RADICALS INCLUDE AN ACYL RADICAL OF A DETERGENT-FORMING MONOCARBOXY ACID HAVING AT LEAST 8 AND NOT OVER 32 CARBON ATOMS IN CONJUNCTION WITH THE ACYL RADICAL OF AN ALPHA HALOGEN MONOCARBOXY ACID HAVING NOT OVER 6 CARBON ATOMS, AND IN WHICH THE ALCOHOLIC RADICAL IS THAT OF CERTAIN HYDROPHILE POLYHYDRIC SYNTHETIC PRODUCTS; SAID HYDROPHILE SYNTHETIC PRODUCTS BEING OXYALKYLATION PRODUCTS OF (A) AN ALPHA-BETA ALKYLENE OXIDE HAVING NOT MORE THAN 4 CARBON ATOMS AND SELECTED FROM THE CLASS CONSISTING OF ETHYLENE OXIDE, PROPYLENE OXIDE, BUTYLENE OXIDE, GLYCIDE AND METHYLGLYCIDE, AND (B) AN OXYALKYLATION-SUSCEPTIBLE, FUSIBLE, ORGANIC SOLVENT-SOLUBLE, WATER-INSOLUBLE PHENOL ALDEHYDE RESIN; SAID RESIN BEING DERIVED BY REACTION BETWEEN A DIFINCTIONAL MONOHYDRIC PHENOL AND AN ALDEHYDE HAVING NOT OVER 8 CARBON ATOMS AND HAVING ONE FUNCTIONAL GROUP REACTIVE TOWARD SAID PHENOL; SAID RESIN BEING FORMED IN THE SUBSTANTIAL ABSENCE OF PHENOLS OF FUNCTIONALITY GREATER THAN TWO; SAID PHENOL BEING OF THE FORMULA 